According to Precedence Research, the global electric vehicle range extender market size was estimated at USD 1.19 billion in 2024 and is expected to hit around USD 2.75 billion by 2034 with a CAGR of 8.74%.
Electric Vehicle Range Extender Market Key Points
- North America dominated the global market in 2024, accounting for the largest share of 46%.
- Among products, the ICE range extender segment held the leading position with a 74% market share.
- In terms of vehicle type, passenger vehicles generated the highest revenue, contributing 85% of the market share in 2024.
- Based on components, the battery pack segment emerged as the top contributor, securing 43% of the market share.
What is an Electric Vehicle Range Extender?
An Electric Vehicle (EV) Range Extender is a supplementary power source used in electric vehicles to increase their driving range beyond what the onboard battery alone can provide. It is typically a small internal combustion engine (ICE) or other generator system that produces electricity to recharge the battery when it runs low, rather than directly driving the wheels. This allows EVs to travel longer distances without frequent stops for charging, effectively addressing “range anxiety”—a common concern among EV users.
How Does a Range Extender Work?
The range extender is activated only when the battery’s charge drops to a predefined level. Once engaged, it generates electricity which either powers the electric motor directly or recharges the battery. Unlike hybrid vehicles where the combustion engine may power the wheels directly, a range extender in EVs only functions as an electricity generator, ensuring that the driving experience remains primarily electric.
Common Types of Range Extenders:
Internal Combustion Engine (ICE) Range Extender – The most widely used, often powered by gasoline or diesel.
Rotary Engines – Known for being compact and lightweight.
Fuel Cell Range Extenders – Generate electricity using hydrogen, emitting only water vapor.
Turbine Range Extenders – Use small turbines to generate electricity, offering high efficiency in a compact design.
Regional Outlook of the Electric Vehicle Range Extender Market
United States
The U.S. leads the North American electric vehicle (EV) range extender market, with an estimated market size of USD 380 million in 2024, projected to reach around USD 920 million by 2034 at a CAGR of 9.24%. The country benefits from technological advancements, increasing battery demand, and strong government initiatives supporting EV adoption. These factors, combined with a surge in electric vehicle sales, are driving robust growth in the range extender segment in the U.S.
United Kingdom
Within Europe, the UK dominates the EV range extender market. The region is expected to experience the fastest growth globally, with a projected CAGR of 13% during the forecast period. The UK’s leadership is attributed to rising sales of electric and hybrid vehicles and the presence of major market players. Government incentives and a strong push towards electrification further fuel market expansion in the UK.
Europe (Excluding UK)
Other European countries are also witnessing significant growth, supported by increasing adoption of electric and hybrid vehicles and favourable regulatory environments. The broader European market is characterized by rapid technological advancements and collaborations between OEMs and EV manufacturers, enhancing the deployment of range extender technologies.
Asia-Pacific
While specific country-level data is not detailed, the Asia-Pacific region is identified as a growth area for the EV range extender market. The region’s expansion is driven by the rising adoption of electric vehicles in both developed and developing countries, supported by government incentives and growing environmental awareness. Collaboration between manufacturers and OEMs is also strengthening the market position in Asia-Pacific.
North America North America held a dominant 46% revenue share in 2024, with the U.S. as the primary market. However, Canada and Mexico are also experiencing growth, albeit at a slower pace, due to increasing EV adoption and supportive policy measures.
Segmental Outlook of the Electric Vehicle Range Extender Market
By Product
The internal combustion engine (ICE) range extender segment dominates the market, accounting for about 74% of revenue share in 2024. This segment’s growth is driven by its relatively low cost and the widespread adoption of hybrid electric vehicles globally. Meanwhile, the fuel cell range extender segment is the fastest growing, reflecting increasing adoption of fuel cell vehicles worldwide. Fuel cell range extenders are particularly attractive due to their efficiency and the global shift toward cleaner energy sources.
By Vehicle
Passenger vehicles hold the largest share, contributing approximately 85% of the market revenue in 2024. The integration of range extender technologies in passenger vehicles is a key competitive strategy among market leaders, further supported by government initiatives promoting EV adoption in this segment. Commercial vehicles, however, represent the fastest-growing segment. Countries like the UK and the U.S. are increasingly integrating range extenders into commercial fleets, driving rapid expansion in this category.
By Component
Battery packs are the leading component, accounting for around 43% market share in 2024. Their efficiency and longevity typically lasting around five years make them a preferred choice for electric vehicles. The electric motor segment is experiencing the fastest growth, propelled by technological advancements and the rising demand for fuel cell vehicles, as electric motors are integral to fuel cell range extender systems.
Role of Key Companies in the Electric Vehicle Range Extender Market
Nissan
Nissan is a pioneer in range extender technology, notably through its e-POWER system. This system uses a gasoline engine exclusively to generate electricity for the battery, which then powers the electric motor. Nissan’s approach bridges the gap between hybrids and pure electric vehicles, making EVs more accessible in markets with limited charging infrastructure.
Delta Motorsport
Delta Motorsport specializes in developing compact and lightweight range extender modules for electric vehicles. Their engineering solutions are often tailored for niche and performance applications, helping automakers and specialty vehicle manufacturers enhance EV range without significant weight or complexity increases.
Magna International
Magna International is a major automotive supplier providing modular range extender systems and components. Their scalable solutions support both passenger and commercial vehicles, enabling global automakers to integrate range extender technology efficiently and flexibly.
General Motors (GM)
GM was an early leader in range extender technology with the Chevrolet Volt, which used a battery-electric drivetrain supplemented by a gasoline engine generator. This approach demonstrated the practicality of range-extended EVs and influenced subsequent hybrid and electric vehicle designs.
Ballard Power Systems
Ballard Power Systems specializes in hydrogen fuel cell technology, supplying fuel cell-based range extenders for commercial vehicles and buses. Their zero-emission solutions are increasingly adopted in regions focusing on hydrogen infrastructure and clean transportation.
Mahle
Mahle develops efficient internal combustion engines and thermal management systems specifically for use as range extenders in electric vehicles. Their technology supports better integration and performance of range extender systems in both passenger and commercial EVs.
Ceres Power
Ceres Power focuses on solid oxide fuel cell (SOFC) technology, offering efficient and compact fuel cell systems for range extender applications. Their solutions are particularly valued in scenarios requiring low emissions and high efficiency.
BMW
BMW is known for its i3 REX (Range Extender), which uses a small gasoline engine to generate electricity when the battery is low. This model helped popularize the concept of range extenders by addressing range anxiety while maintaining the electric driving experience.
Rheinmetall
Rheinmetall develops and supplies range extender modules, especially for commercial and specialty vehicles. Their expertise in powertrain and thermal management systems ensures that range extenders meet high performance and emissions standards.Plug Power
Plug Power is a leader in hydrogen fuel cell solutions, providing fuel cell-based range extenders for electric vehicles, particularly in commercial and logistics sectors. Their technology supports zero-emission goals and the broader adoption of hydrogen as a clean energy source.
